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1. PUBLISHABLE SUMMARY

Summary of the context and overall objectives of the project (For the final period, include theconclusions of the action)

CO2 generation is an inherent consequence of cement production due to the calcination of limestone(CaCO3 converted to CaO and CO2). There are no alternative methods to produce clinker, andthus cement, without releasing CO2 from CaCO3. Furthermore, cement demand has been growingcontinuously since the beginning of last century. Altogether, the most viable option to reducesignificantly greenhouse gas emissions from the cement industry is to retrofit CO2 capture to existingcement plants. Most of the existing/envisaged CO2 capture technologies have been developed forpower plants, and will need targeted development to enable retrofitting of cement plants. Whenconsidered for the cement sector, capture technologies were, at the startup of CEMCAP, typicallyat Technology Readiness Level (TRL) 4-5 or lower, with the exception of the amine technologydemonstrated on-site (TRL8) at the plant of CEMCAP partner Norcem.

The primary objective of CEMCAP is to prepare the ground for large-scale implementation of CO2capture in the European cement industry. The project has been developed for broadening the portfolioof CO2 capture technologies for the cement industry and bringing them to a higher TRL level andthus closer to deployment.

To achieve its primary objective, CEMCAP will• Leverage to TRL6 for cement plants the oxyfuel clinker cooler, calciner, and burner, and threefundamentally different post combustion capture technologies (chilled ammonia process (CAP),membrane-assisted CO2 liquefaction, calcium looping (CaL) capture).• Identify the CO2 capture technologies with the greatest potential to be retrofitted to existing cementplants in a cost- and resource-effective manner, maintaining product quality and environmentalcompatibility.• Formulate a techno-economic decision-basis for CO2 capture implementation in the cement industry,where the current uncertainty regarding CO2 capture cost is reduced by at least 50%.

Work performed from the beginning of the project to the end of the period covered by the reportand main results achieved so far (For the final period please include an overview of the resultsand their exploitation and dissemination)

A framework document has been published on the CEMCAP website that provides a commonknowledge basis about cement plant operation and provides input data for experimental and analyticalresearch. This will enable a consistent comparative techno-economic analysis.

Based on the framework, the following modelling and simulation work was performed:• A reference cement plant was simulated to serve as basis for future capture technology integrationstudies.• A cement plant with MEA CO2 capture was simulated, and will serve as a reference for the techno-economic evaluation of the CEMCAP technologies.• A model of a full oxyfuel cement plant with oxyfuel burner, calciner and clinker cooler wasdeveloped.

Ref. Ares(2017)4056272 - 16/08/2017

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• Extensive simulations, including heuristic parameter optimization of a full-scale CAP system, wereperformed in order to find a set of operating conditions that minimizes the CAP energy consumption.• Process simulations for membrane-assisted CO2 liquefaction were performed to establish capture-process data, preparing for pilot-scale testing.• Process simulations of two CaL process integration options (tail-end CaL and highly integrated CaL)were performed, supported by fluidized-bed and entrained-flow carbonator models.

For all capture technology process models, model parameters will be updated as results becomeavailable from the experimental activities in CEMCAP. This work is in progress for both the oxyfuelcomponents, CAP, membrane-assisted CO2 liquefaction and CaL technology.

Economic analyses of the reference cement plant without and with MEA CO2 capture were performedto provide a basis for the future techno-economic comparison of technologies, and methodologies forcost estimation of non-standard process components were established. First process integrations ofthe CEMCAP technologies in the reference cement plant were done and preliminary energy-relatedkey performance indicators (KPIs) were calculated.

Experimental research is in CEMCAP carried out for three oxyfuel cement plant components (burner,calciner and clinker cooler) and for three different post-combustion capture technologies (chilledammonia, membrane-assisted CO2 liquefaction and calcium looping).

The progress in testing and experiments of oxyfuel technologies for cement plants is after two years:• Two experimental campaigns have been conducted in a 500 kWth burner test facility with petcokeas fuel. A third experimental campaign is planned, for a different fuel.• Calcination experiments have been conducted in a 50 kW electrically heated entrained flowreactor facility for both air and oxyfuel scenarios. Tests have been carried out for different reactortemperatures and residence times, and additional tests are in progress.• An oxyfuel clinker cooler prototype was installed at the HeidelbergCement plant in Hannover. Theprototype was tested in several campaigns over a period of 6 months.

Progress in the testing and development of post-combustion capture technologies for cement plants is:• Pilot-plant tests of a CAP CO2 absorber without fluegas impurities and the direct contact coolerwere concluded.• A setup for CO2 membrane performance testing was assembled, and a set of suitable membranesfor the capture process was acquired.• A wide range of CaL operation parameters were screened in a 30 kW CaL test facility. Oneexperimental campaign was carried out in a 200 kW pilot facility, while a second campaign is planned.

A report on the status and knowledge of different routes for post capture CO2 management, where thepoint of view of the cement industry is adopted, is in progress. The following five routes are selectedfor techno-economic evaluation: (i) Mineralization to MgCO3, (ii) geological sequestration, (iii) CO2hydrogenation to ethanol, (iv) CO2 polymerization to polypropylene carbonate, and (v) food-gradeCO2.

The CEMCAP website is continuously updated with news, presentations and results from theconsortium. CEMCAP is active on twitter (@cemcap_co2) with 157 tweets so far, and the projecthas published four newsletters and blog posts, respectively. The first out of three joint CEMCAP/ECRA workshops has been arranged with focus on knowledge transfer between the partners and tothe ECRA CCS steering committee.

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Progress beyond the state of the art, expected results until the end of the project and potentialimpact (including the socio-economic impact and the wider societal implications of the projectso far)

All the experimental research in CEMCAP is progressing CO2 capture from cement plants beyondstate-of-the-art, with demonstrations in industrially relevant environments (TRL6).

The oxyfuel pilot-scale clinker cooler is unprecedented in its innovative design, just as the oxyfuelburner adaptations and the new oxyfuel nozzle design are unprecedented. Calcination is testedin a CO2 rich-environment relevant for oxyfuel, and CaL with a high substitution rate of CO2absorber has not been tested before. CAP technology has never before been tested for such highCO2 concentrations (up to 35%). Furthermore, the CEMCAP framework provides an unprecedentedassembly of knowledge and data for simulations of CO2 capture from cement plants.

To summarize, CEMCAP is progressing towards identifying the most cost- and resource effectiveoptions for CCS in the cement industry thereby expanding the options for CCS deployment in Europe.

Address (URL) of the project's public website

http://www.sintef.no/cemcap/

Experimental facility at IFK, University of Stuttgart, for entrained calciner tests.

Preparing the rig for experiments of membrane-assisted CO2 liquefaction.

CEMCAP present at GHGT13 in Lausanne to disseminate results on CO2 capture from

cement plants.

Calcium looping pilot plant at IFK (University of Stuttgart).

Oxyfuel clinker cooler pilot plant.

Experimental rig used for the Direct Contact Cooler (DCC) tests carried out by GE Power

Sweden.

An oxyfuel burner